Method of making an absorbent composite and absorbent articles empolying the same

ABSTRACT

Disclosed is a disposable absorbent article with a chassis body having a first end margin and a second end margin longitudinally spaced from the first end margins. The article further includes a topsheet, a backsheet, and an absorbent composite disposed between the topsheet and backsheet. The absorbent composite includes a first fabric, a second fabric, and absorbent particles disposed between the first and second fabric. The first fabric is intermittently attached to the second fabric to define a plurality of containers situated therebetween, each containing an aggregate of absorbent particles. The absorbent composite includes regions of such absorbent particles aggregates, including a primary region having containers of a first size and a secondary region having a plurality of containers of a second size.

The present application is a Continuation application of U.S.application Ser. No. 14/026,927 filed on Sep. 13, 2013 (now allowed),which claims the benefit of U.S. Provisional Application Ser. No.60/801,620, filed on Mar. 15, 2013 (now expired), which disclosure ishereby incorporated by reference for all purposes and made a part of thepresent disclosure.

BACKGROUND

The present disclosure relates generally to a method of making anabsorbent composite. The present invention also relates generally todisposable absorbent articles employing absorbent composites. Suchdisposable absorbent articles include diapers, training pants, adultincontinence products, bodily exudates absorbing products, femininehygiene products, and other absorbent products (collectively “disposableabsorbent articles”).

Prior disposable absorbent articles typically employ three basicstructural elements: a topsheet that forms the inner surface, abacksheet that forms the outer surface, and an absorbent core that isinterposed between the topsheet and the backsheet. The topsheet isdesigned to allow liquid to pass from outside the absorbent articlethrough the topsheet and into the absorbent core. The topsheet may bemade out of a range of liquid and vapor permeable hydrophilic orhydrophobic materials. The permeability of the topsheet can be increasedby using surface activation agents (“surfactants”). Surfactants lowerthe surface energy or the contact angle of the liquid-solid interfaceand facilitate the liquid's passage through the topsheet.

The backsheet is designed to prevent fluid from passing from theabsorbent core through the backsheet and out of the absorbent article.The backsheet may be made out of an impermeable film that extends thefull width of the article or a combination of cloth-like material andimpermeable film. The backsheet may also have vapor transmissionproperties (“breathability”) that allow vapor to pass through thebacksheet without releasing fluid stored in the absorbent core. Thebacksheet may also be made from a liquid impermeable but vaportransmittable non-woven material such as spunbond, melt-blow, spun-bond(“SMS”); spun-bond, melt-blown, melt-blown, spun-bond (“SMMS”); micro,nano, or splittable fibers; spun melt or spun laced; carded; and thelike.

The absorbent core is designed to contain and distribute fluid thatpasses through the topsheet. A typical absorbent core is made out of ahigh or super absorbent polymer (SAP) stabilized by an absorbent matrix.SAP is commonly made out of materials such as polyvinyl alcohol,polyacrylates, various grafted starches, and cross-linked sodiumpolyacrylate. SAP can be in the form of particles, fibers, foams, web,spheres, agglomerates of regular or irregular shapes, and film. Theabsorbent matrix is typically a de-fiberized wood pulp or similarmaterial. The absorbent matrix is very bulky relative to the topsheet,backsheet, and SAP. Most of a diaper's thickness comes from theabsorbent core.

Increasingly, consumers of absorbent articles are demanding thinnerabsorbent articles. To meet these demands, manufactures are decreasingthe thickness of absorbent articles by decreasing the amount ofabsorbent matrix used in absorbent cores. Although the resultingabsorbent cores are thinner, they suffer in performance. As the amountof absorbent matrix is reduced, it is less effective in stabilizing theSAP—preventing the SAP from migrating within the absorbent core. As SAPmigrates within the core, the absorbent core losses its effectivenessand no longer has uniform absorbency. For example, SAP that is notcontained tends to bunch up in wetted areas and is inefficient forhandling subsequent discharges.

Manufactures have attempted to solve this problem by creating small,individual SAP pockets or by gluing the SAP. These solutions, however,have been largely unsuccessful. The SAP pockets merely limit themigration to movement within the pockets. However, because there isstill a movement of the particles, the absorbent core does not exhibituniform absorbency. Gluing the SAP stabilizes the SAP, but results in anuncomfortably stiff absorbent core and a loss in the SAP's swellingcapacity.

Accordingly, there exists a need for an improved absorbent product thatcontinues the trend of decreasing product thickness, while minimizingproduct stiffness and otherwise exhibiting excellent absorbency. Thespecification of U.S. Pat. No. 8,148,598, which is commonly assigned anddesignates at least one common inventor as the present application,describes a prior improvement to the state of the art and serves asbackground to the present disclosure. The ‘’598 patent document ishereby incorporated by reference, in its entirety, for all purposes andmade a part of the present disclosure. The present disclosure may, inone respect, be regarded as continuing and furthering the effort toprovide improved absorbent products and methods of manufacturing.

BRIEF SUMMARY

In one aspect, the disclosure provides improved absorbent composites andmethods of making the composite. Various embodiments are disclosed inwhich aggregates of absorbent particles are strategically located and/orconstituted between a top layer and bottom layer, and across the expanseof the composite or core. By varying the position of the aggregates orthe restrictions on the aggregates, the performance and capabilities ofthe absorbent composite may be managed or influenced. In certainembodiments, the aggregates of absorbent particles are situated incontainers or pockets. In further embodiments, the size, spacing,arrangement, and\or geometry or shape of the containers or pockets arespecifically provided to achieve certain core fluid handling properties.

In one embodiment, a disposable absorbent article includes a chassisbody defined by a first end margin and a second end marginlongitudinally spaced from the first end margin, the end marginspartially defining front and back waist regions that are fastenableabout a waist of a user. The article further includes a topsheet, abacksheet, and an absorbent composite disposed between the topsheet andbacksheet. The topsheet and backsheet define longitudinal and lateralmargins of the chassis body. The absorbent composite includes a firstfabric and a second fabric bonded to the first fabric. Furthermore,absorbent particles are adhered between the first and second fabric,wherein the first fabric is intermittently attached to the second fabricto define a plurality of containers situated between the first fabricand the second fabric and containing an aggregate of absorbentparticles. The absorbent composite includes regions of containers ofabsorbent particles aggregates including a primary region havingcontainers of a first size and a secondary region having a plurality ofcontainers of a second size different from the first size.

The present disclosure is of an absorbent composite that, in someembodiments, does not require an absorbent matrix and a novel method ofmaking the absorbent composite. The present document also discloses anabsorbent article that incorporates the absorbent composite. Theabsorbent composite provides for an absorbent article that can be madevery thin and pliable, while at the same time retaining enough SAP toprovide sufficient absorbency and dry and wet integrity (uniformabsorbency). Although using the absorbent composite in a diaper isdescribed, one skilled in the art would readily understand that anabsorbent composite made according to the inventive process may be usedin a wide variety of absorbent products.

The present disclosure is also directed to an improved absorbent articleincorporating the absorbent composite.

In one example, a method is described for manufacturing a compositesheet, comprising the steps of positioning a first fabric to receiveparticles, depositing particles on the first fabric, applying adhesiveto a second fabric, positioning the second fabric relative to the firstfabric, and forming bond sites that extend between the first and secondfabric. The method may further include an article in which the particlescomprise SAP particles, skin care particles, odor absorbing particles,binder particles, ion exchange particles, and combinations thereof.Still further, the method may include the step of coating the particleswith a hydrophobic material.

The method may include conforming the first fabric to a surface. Thesurface may include recesses that form pockets or containers in thefirst fabric when it is conformed to the surface. The SAP particles maybe guided into the pockets formed in the first fabric. Suction may beused to conform the first fabric to the surface. The adhesive applied tothe second fabric may be applied in a concentration sufficient to securean effective amount of dry particles. That concentration is generallybetween 1 to 100 grams per square meter. More specifically, the adhesivemay be applied in a concentration of between 5 and 75 grams per squaremeter, or even more optimally, between 12 and 50 grams per square meter.The adhesive may be applied in a manner such that the total amount ofadhesive engaging particles is between 1 and 100 grams per square meter.The inventive method may further includes a step of applying adhesive tothe first fabric before particles are deposited on the first fabric.

The bond sites suitable for the method may be bond lines, which may becontinuous or discontinuous and may define pockets or other shapes anddesigns. Alternatively, the bond sites may be bond points. The bondsites may be positioned relative to particles and/or arranged to preventstraight line particle migration of more than 2 inches.

Alternatively, the method entails positioning a first fabric to receiveparticles, positioning particles on the first fabric, securing theparticles relative to the first fabric, positioning a second fabric overthe particles, and forming bond sites that join the first fabric to thesecond fabric. The bond sites may be discrete points spaced to inhibitthe migration of particles. The bond sites may also be bond lines spacedto inhibit the migration of particles, or bond lines that are connectedto form a single bond line. The bond lines may be arranged to formpockets within which some particles are positioned. The particles may beSAP particles, skin care particles, odor absorbing particles, binderparticles, ion exchange particles, and combinations thereof. Theparticles may be secured to the first fabric with adhesive, thermalplastic, or combinations thereof. In addition to or in the alternative,the particles may be secured to the second fabric with adhesive, thermalplastic, or combinations thereof. Furthermore, shapes may be formed inthe first fabric for receiving particles.

A disposable absorbent article according to the disclosure may comprisea topsheet, a backsheet, and an absorbent core disposed therebetween,wherein at least a portion of one of the backsheet, topsheet, andabsorbent core. The absorbent core is an absorbent composite comprisinga first fabric, a second fabric bonded to the first fabric, andparticles adhered between the first and second fabric. The particles maybe SAP particles, skin care particles, odor absorbing particles, binderparticles, ion exchange particles, and combinations thereof.

Alternatively, an absorbent layer may be provided that is supported onthe backsheet, such that a section of the backsheet provides the secondfabric of the absorbent composite. The backsheet may further comprises afirst backsheet layer, a second backsheet layer and SAP particles in aconcentration of about 20 gsm positioned there between and the secondback sheet layer is an SMS having a basis weight in the range of about10 gsm to 60 gsm. The absorbent layer may be adhered between the firstand second fabric with an adhesive concentration of between 1 and 100grams per square meter. The first fabric may be bonded to the secondfabric at discrete points, which discrete points may define pockets.Further, the first fabric may be bonded to the second fabric along aplurality of bond lines, which bond lines may define pockets.

The absorbent core may also comprise a first fabric, a second fabric,bond sites at which the first fabric is connected to the second fabric;and an absorbent layer of particles adhered between the first and secondfabric. The particles may be SAP particles and/or other beneficialparticles. The absorbent layer may be supported underneath a section ofthe topsheet, such that the section of topsheet provides the secondfabric of the absorbent composite. The absorbent layer may be supportedon a section of the backsheet, such that the backsheet section providesthe first fabric of the absorbent composite.

In some embodiments, the disposable absorbent article may include aconcentration of SAP particles in the absorbent layer of between about50 and 650 grams per square meter. The SAP particles may also be coatedwith a hydrophobic material to retard the initial receipt of liquid bythe SAP particles in the absorbent layer. The bond sites may define aplurality of continuous lines that inhibit the movement of the SAPparticles of the absorbent layer. The continuous lines may be shaped toform pockets between the first and second fabrics. The bond sites maydefine a plurality of discontinuous lines that inhibit the movement ofthe SAP particles of the absorbent layer. The discontinuous lines may beshaped to form pockets between the first and second fabric.

In the yet another embodiment, the bonds may be positioned alongperiphery of pockets of particles. The bonds may form a pattern such asherringbone, bricklayer, circles, triangles, dots, dashes, rectangles,and combinations thereof. The yet another embodiment may also includeloose particles positioned between the first and second sheets.

The foregoing has outlined rather broadly the features and technicaladvantages of the present disclosure in order that the detaileddescription that follows may be better understood. Additional featuresand advantages will be described hereinafter. It should be appreciatedthat the specific embodiments disclosed may be readily utilized as abasis for modifying or designing other structures for carrying out thesame purposes. It should also be realized that such equivalentconstructions do not depart from the disclosure as set forth in theappended claims. The features which are believed to be characteristic ofthe disclosure, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, referenceis now made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIG. 1 is a schematic of one embodiment of a method of making anabsorbent composite using calendar rolls;

FIG. 2 is a schematic of another embodiment of a method of making theinventive absorbent composite using calendar rolls;

FIG. 3 is a schematic of the method shown in FIG. 1 with an additionalenergy source;

FIG. 4 is a variation of the method shown in FIG. 1 that uses ultrasonicbonding techniques instead of calendar rolls;

FIG. 5 is a variation of the method shown in FIG. 2 that uses ultrasonicbonding techniques instead of calendar rolls;

FIG. 6 is an illustration of various potential bonding patterns that maybe used in the method and absorbent article;

FIG. 7 is a cross sectional illustration of a pockets formed by themethod and utilized in the absorbent article;

FIG. 8 is a perspective view of a disposable absorbent article embodyingthe absorbent composite;

FIG. 9 is a top plan view of the disposable absorbent article of FIG. 8in a flat and extended condition;

FIG. 10 is an exploded view of the disposable article of FIG. 8;

FIG. 11 is a partial cross-sectional view of an absorbent core utilizingthe absorbent composite and employed by an absorbent article;

FIG. 12 is partial cross-sectional view of an absorbent core utilizingan alternative embodiment of the inventive absorbent composite andemployed by an alternative absorbent article;

FIG. 13 is a cross-sectional view of an absorbent article employing inthe leg cuffs an absorbent composite;

FIG. 14 is a cross-sectional view of an absorbent article employing inthe leg cuffs a saturated absorbent composite;

FIGS. 15A-15D are simplified illustrations of an absorbent compositeaccording to the present disclosure, with particular attentions to anarrangement of aggregates of absorbent particles across the composite;

FIG. 16A is a simplified illustration of a prior art SAP sandwich;

FIG. 16B is a simplified illustration of an SAP structure (sandwich) inaccordance with the present disclosure;

FIGS. 17A-17D are simplified illustrations in cross-sectional view ofpockets and fluid properties characterizing the arrangement of pockets,in accordance with the disclosure;

FIG. 18A is a simplified schematic of a process of making an absorbentcomposite according to the disclosure; and

FIGS. 18B-18C are illustrations or photographs of exemplary componentsof the process described in respect to FIG. 18A.

DETAILED DESCRIPTION

Upon review of the detailed description and the accompanying drawingsprovided herein, it will be apparent to one of ordinary skill in the artthat an absorbent composite made according to the present disclosure maybe used in disposable absorbent articles, and more particularly, indisposable absorbent articles, such as diapers, training pants or otherincontinence products. Accordingly, the present disclosure shall not belimited to the structures and processes specifically described andillustrated herein, although the following description is particularlydirected to an absorbent composite that is used in a disposable diaper.The term “absorbent article” or “absorbent garment” with which thepresent disclosure is associated, includes various types of disposablearticles and garments which are placed against or in proximity to thebody of the wearer so as to absorb and contain various bodily exudates,bodily fluid, or biofluid.

Perhaps to gain a better understanding and appreciation of theparticular contributions and improvements which are introduced in thepresent disclosure, reference may be first made to the improvementsearlier disclosed in U.S. Pat. No. 8,148,598. These earlier improvementsare described in respect to FIGS. 1-14. Some of the teachings andsuggestions therein may, in addition to serving as background knowledgein the art, translate to certain specific embodiments of the presentdisclosure (which will become apparent to one skilled in the relevantart given the present disclosure).

In FIG. 1, a fabric 125 is shown as it is dispensed from roll 120 andcarried along a production line on a conveyer belt 100. The fabric 125may be thermal plastic material that may be a woven, nonwoven, film, ora combination thereof. The fabric 125 is secured to the conveyor belt100 by a vacuum system 110. The vacuum system 110 serves to confirm thefabric 125 to the convey belt 100.

In one embodiment, the surface of the conveyor belt 100 has recessedportions that form cups in the fabric 125 as the fabric is pulledagainst the surface of the conveyor belt 100. The surface of theconveyor belt 100 is not limited to constructions that form cups in thefabric but, instead, may be configured with a number of differentsurface shapes and sizes. Examples include ridges, raised shapes, andholes. In addition, the surface shapes may be distributed uniformly ornon-uniformly across the width and length of the conveyor belt.Alternatively, the conveyor belt 100 may be flat. In applications inwhich the conveyor belt 100 has holes or other similar constructions,the depth of the pockets formed in the fabric 125 may be varied by theforce of the vacuum system 110, the elasticity of the fabric 125, or acombination thereof. Additionally, heat may be used to increase theelasticity of the fabric 125 as the fabric is pulled against the surfaceof the conveyor belt 100. Heat may be applied to the fabric by way of aheated conveyor belt or any other means known in the art. The vacuum 110may be applied uniformly across the surface of the conveyor belt 100 orat selected locations. For example, in a configuration in which thesurface of conveyor belt 100 has depressions, vacuum may be applied onlyat the depressions.

The SAP particles 135 are then deposited on the fabric 125 by an SAPdispenser 130. The SAP dispenser 130 may be configured to position SAPparticles in their desired position on the first fabric or may beconfigured merely to deposit SAP particles on the first fabric, whereinthe SAP particles are position by another means. One skilled the artunderstands that multiple SAP dispensers 130 may be used. The SAPparticles 135 may be deposited, positioned, or both on the fabric 125 bywind or other known methods. Alternatively, the conveyor belt shown inFIG. 1 may be inverted so that the vacuum system 110 applies suctionfrom above. In such a configuration, the fabric 125 is carried over asupply of SAP particles 135 and the SAP particles are held onto thesurface of fabric 125 by vacuum system 110. In an alternativeembodiments, SAP dispenser 130 may include skin care particles such asion exchange resins, deodorant, anti-microbial agents, binder particles,or other beneficial particles. Further, although the preferredembodiment is directed to SAP particles, the methods discloses hereincan be used with any combination of the above referenced particles,including combinations that do not include SAP. Alternatively, separatedispensers advantageously positioned along the production line (notshown) may be used to deposit different types of particles such as, forexample, skin care particles.

The SAP particles 135 are positioned and concentrated on the fabric 125according to a number of alternative methods. In one embodiment, thevacuum system 110 and fabric 125 may be configured to allow the vacuumsystem 110 to pull the SAP particles 135 against the surface of thefabric 125 uniformly or in particular areas. In another embodiment, theshape of the fabric 125 guides the SAP particles 135 into position. Forexample, when the fabric 125 is shaped to form pockets, the SAPparticles 135 roll into the pockets as a result of the vacuum system110, the vibration of the conveyor belt, wind, the angle of the conveyorbelt, or combinations thereof. Alternatively, the SAP dispenser(s) 130may be positioned and controlled to dispense SAP particles 135strategically across the surface of fabric 125, which strategicpositioning includes but is not limited to alignment or nonalignmentwith the machine direction, offset, or randomly. Further, SAP may bepositioned such that there are zones without SAP particles. Stillfurther, SAP particles may be positioned using adhesive such as byapplying adhesive to specific locations on a surface, depositing SAPparticles on the surface. Still further, SAP particles may be positionedon both fabrics 125 and 155.

Once SAP particles have been deposited and positioned on fabric 125, asecond fabric 155 is introduced into the production line from roll 150.The second fabric 155 may be selected from a variety of materialsincluding spun-bonded thermoplastic or similar woven or nonwovenmaterial, film, or combinations thereof.

The adhesive 145 is applied to the SAP particles 135 in a number ofways. FIG. 1 shows the adhesive 145 applied to the fabric 155.Alternatively, the adhesive 145 may be applied to the fabric 125 and SAPparticles 135, fabric 125 before the SAP particles 135 are deposited onthe fabric 125, or directly to the SAP particles before they aredeposited on the fabric 125. In still another embodiment, the adhesive145 is applied at the point where fabrics 125 and 155 are jointedtogether. In still another embodiment, multiple coats of adhesive areapplied. For example, adhesive 145 may be applied to the fabric 125before the SAP particles 135 are deposited, to the SAP particles 135after they have been positioned, to the fabric 155, or a combinationthereof. Alternatively or in addition to the above embodiments, binderparticles may be mixed with the SAP particles 135. Additionally, theadhesive may be applied uniformly, randomly, or in a specific pattern,depending the desired absorbent properties of the finished composite.

The adhesive is applied according to a number of methods know to thoseskilled in the art. For example, the adhesive may be sprayed, rolled, orspun onto the surface of fabric 155. The adhesive may be hydrophobic,hydrophilic, biodegradable, bioderived, or combinations thereof. Thepreferred adhesive is hydrophobic. The concentration of adhesive in acoat varies between 1 and 100 grams per square meter (“GSM”). Optimally,the concentration is between 5 and 75 GSM. In a preferred embodiment,the concentration is between 12 and 50 GSM. Additionally, enoughadhesive should be applied to cover at least 25% of the targeted area.

Fabrics 125 and 155 are then bonded together. FIG. 1 shows a thermalbonding system in which calendar rolls 160 and 170 are used. However,other bonding systems/methods may be used. For example, the ultrasonicbonding system of FIGS. 4 and 5 may be used. Adhesive 145 retains theSAP particles 135 in a relatively fixed position with respect to thefabrics during the bonding process and subsequent to the bondingprocess. The bond pattern may be aligned with the distribution of theSAP particles 135. Alternatively, the bond pattern may not be alignedwith the distribution of the SAP particles 135. In such embodiments, thebonding equipment may be adapted to nudge the SAP particles 135 asideprior to bonding or to bond through the SAP particles 135. Theseembodiments eliminate the need to synchronize the pond points with thedistribution of SAP particles.

Fabrics 155 and 125 are shown as two materials. However, one skilled inthe art understands that the fabrics may actually be part of the samematerial. In such a configuration, the unitary fabric is folded to coverthe SAP particles. Alternatively, the edges of fabric 125 may be foldedprior to applying the second fabric 155. In embodiments in which fabrics125 and 155 are separate, fabrics 125 and 155 may be the same or adifferent material. Additionally, fabric 155 may be sized to coverspecific areas, such as the center section, of fabric 125.

Once the fabrics have been bonded together, the absorbent composite 195is collected on rewinder 200.

In a method illustrated in FIG. 2, the fabric 125 is transported alongthe conveyer belt 100. As fabric 125 is transported along the conveyerbelt 100, a thin coat of adhesive 145 is applied to fabric 125. As withthe method of FIG. 1, the adhesive may be applied uniformly, randomly,or in a specific pattern, depending the desired absorbent properties ofthe finished composite. Although the adhesive 145 is shown being appliedbefore the SAP Particles 135 are deposited, alternate embodiments areenvisioned. For example, the adhesive may be applied according to theembodiments described with respect to FIG. 1.

Following the application of the adhesive, SAP particles 135 aredeposited and positioned on the fabric 125. The SAP particles 135 may bedeposited directly on fabric 125, as shown in FIG. 2, or indirectly,such as by wind blowing SAP particles across fabric 125. The weight ofthe SAP particles aids in securing the fabric 125 to the conveyor belt100. Additionally, the SAP particles may be positioned in a mannersimilar to that disclosed for FIG. 1.

A second fabric 155 is then fed into the production line from roll 150.The second fabric is positioned to cover the SAP particles 135. Theadhesive 145 prevents the SAP particles from moving freely between thetwo fabrics. The resulting sandwiched construction is then transportedto the calendar rolls for thermal bonding. As described with respect toFIG. 1, the bond pattern may be aligned or not aligned with the SAPparticles 135. The absorbent composite 195 is then collected by rewinder200. As described with respect to FIG. 1, fabrics 125 and 155 may bepart of a single sheet. Additionally, the fabrics may be folded in themanner described for FIG. 1. In another embodiment, the fabric 125 maybe coated with adhesive and pressed on a supply of SAP particles.

FIG. 3 is similar to FIGS. 1 and 2, except that an energy source 900such as an oven or microwave generator is positioned along the assemblyline. The energy source applies heat and or radiation 910 that can beused to melt thermal plastic binder. The amount of heat may also beregulated to melt specific types of particles or fibers, specificsections of the fabrics, or only the outer layers of particles/binder.

FIGS. 4 and 5 are similar to FIGS. 1 and 2, except that the fabrics arebonded together using ultrasonic bonds. FIGS. 4 and 5 show an ultrasonicbonding system (210 a and 210 b). It is readily understood that FIGS.1-5 show different embodiments of the novel method and that aspects ofthe various methods may be advantageously combined depending on theneed.

Important to all combinations, however, is the amount of adhesive 145,binder particles, or combinations thereof applied to the SAP particles135 and the strength of the bonds. As noted with respect to FIG. 1, theoptimal concentration of adhesive is between 12 and 50 GSM, though otherconcentrations are acceptable. In all embodiments, it is important thatthe concentration of adhesive 145 be high enough to inhibit themigration of SAP particles 135. The concentration should not be so high,however, that it coats the SAP particles 135 and reduces SAP swelling.The adhesive should only inhibits the migration of enough SAP particles135 to assure uniform absorbency. Although not shown, one skilled in theart understands that the energy source 900 shown in FIG. 3 can also beapplied in the configurations shown in FIGS. 2, 4 and 5.

FIG. 6 (a) through (q) show various bonding patterns contemplated by themethod. The bonding patterns may completely enclose an area, partiallyenclose an area, or provide local bonding zones. The lines and pointsindicate the bond sites. The solid lines depict bond lines. The bondlines may form open shapes or enclosed shapes, such as can be found inexamples (a) and (c), which depict continuous bond lines that completelyenclose pockets of SAP particles 135 or, as in example (g), separatedistinct regions of the absorbent composite. The dashed lines, such ascan be found in examples (b) and (m), are discontinuous bond pattersthat do not completely enclose pockets of SAP particles 135. In theseconfigurations, the migration of dry SAP particles is inhibited by theadhesive and continuous or discontinuous bond patters. Discontinuouspond patters may be substituted for continuous bond patterns and visaversa. Further, though the FIG. 6 shows either continuous ordiscontinuous bond patters, combinations of discontinuous and continuousbond patters may be used.

FIG. 7 shows a partial cross-section of an absorbent composite 195. FIG.7 shows how bonds 192 may act to separate pockets of SAP particles 135.As noted with respect to the bonding pattern, SAP particles 135 may beentirely enclosed in pockets defined by the bonding pattern, partiallyenclosed in pockets defined by the bonding pattern or merely inhibitedby the bonding pattern. Inhibited in this context means the SAPparticles 135 cannot move directly from one area of the core to anotherarea, but instead, must move around bond sites.

Notably, multiple functions or advantageous properties are obtained inthe absorbent composite by varying the amount of SAP particles, the typeand number of fabrics used, and construction variables such as, theratio of SAP to adhesive, and applying the absorbent composite atvarious locations in the article. Such manufacturing and designtechniques may be incorporated into structural designs and methods ofthe present disclosure.

Additionally, one skilled in the art understands that the process forconstructing a single absorbent composite described above may bemodified to produce a multiple, laminated absorbent composite. Instructures comprising multiple layers, the layers may be sheets ofabsorbent composite 195 that are laminated together to form a singlestructure or alternating layers of fabric and SAP particles 135 thatform a single structure. One skilled in the art understands thatalternating layers may be achieved by applying adhesive to the top offabric 155 (FIG. 1), applying a second layer of SAP particles 135, and athird fabric (not shown). Similarly, additionally layers may be added,limited only by the maximum thickness suitable for the bonding process.

The SAP particles 135 may be coated with a miscible, hydrophobicmaterial. The coating acts as a barrier or membrane that initially slowsthe liquid uptake, thereby saving SAP capacity for additional orsecondary discharges. In this regard, the coating evens out theabsorbency rates between discharges. In the processes shown in FIGS. 1to 5, the coating may be applied prior to the adhesive 145 beingapplied, after the adhesive 145 is applied, or at the same time.Alternatively, the adhesive may be mixed with the coating material.

In one example, a light coating of mineral oil is applied over the SAPparticles 135. The coating retards the initial uptake by the SAPparticles and allows more time for the liquid to spread out in thearticle. Preferably, the mineral oil is applied at a concentration ofabout 0.00001 grams per gram of SAP to about 0.1 grams per gram of SAP(depending on the particular product design). Alternatively, the mineraloil may be applied in specific target zones. In this way, the receivedliquid is encouraged to initially spread to uncoated areas before thecoated areas are activated and begin to swell.

An absorbent composite manufactured by the above-described process maybe used for a disposable absorbent article or as one or more of thecomponents of a disposable absorbent article. The components of anabsorbent article include the backsheet, topsheet, absorbent core,containment walls or cuffs (including leg gathers), backsheet/absorbentcore composite, topsheet/absorbent composite, and combinations thereof.Such constructions are described below in more detail.

FIG. 8 is a perspective view of a disposable absorbent article in theform of a diaper 10. Diaper 10 comprises a topsheet 50, a backsheet 60,and an absorbent core (not shown). The diaper further comprisesupstanding barrier cuffs 34 which extend longitudinally along the diaperand are elasticized to conform to the buttocks of the wearer.Additionally, the diaper includes an elastic band 52 and fasteningelements 26. Element 26, in use, extends to and engages thecorresponding opposing end of the diaper to secure the diaper about thewearer.

FIG. 9 illustrates a composite web structure of the diaper 10 of FIG. 8in a generally flat and unfolded configuration. As will be explainedfurther below, the web structure may be subsequently trimmed, folded,sealed, welded and/or otherwise manipulated to form a disposable diaper10 in a finished or final form. To facilitate description of the diaper10, the description refers to a longitudinally extending axis AA, alaterally extending central axis BB, a pair of longitudinally extendingside edges 90, and a pair of end edges 92 which extend between sideedges 90. Along the longitudinal axis AA, the diaper 10 includes a firstend region or front waist region 12, a second end region or back waistregion 14, and a crotch region 16 disposed therebetween. Each of thefront and back waist regions 12, 14 is characterized by a pair of earregions or ears 18, which are located on either side of a central bodyportion 20 and extend laterally from the side edges 90. A fasteningstructure 26 (e.g., a conventional tape fastener) is affixed to each ofthe ears 18 along the back waist region 14 of diaper 10.

When the diaper 10 is worn about the waist, the front waist region 12 isfitted adjacent the front waist area of the wearer, the back waistregion 14 is fitted adjacent the back waist area, and the crotch region16 fits about and underneath the crotch area. To properly secure thediaper 10 to the wearer, the ears 18 of the back waist region 14 arebrought around the waist of the wearer and toward the front and intoalignment with the ears 18 of the front waist region 12. The securingsurface may be located on or provided by the interior or exteriorsurface of the front waist region 12. Alternatively, the fasteners 26may be located on the ears 18 of the front waist region 12 and madesecurable to the ears 18 of the back waist region 14.

FIG. 10 is an exploded view of the diaper of FIGS. 8 and 9. A suitablediaper structure typically employs at least three layers. These threelayers include a backsheet 60, an absorbent core 46, and a topsheet 50.The diaper structure mayor may not contain a pair of containment wallsor leg cuffs 34 disposed upwardly from the topsheet 50 and preferablyequipped at least with one or more spaced apart, longitudinally elasticmembers 38. It will be shown below that any of these diaper elements ora combination of these elements may be constructed with or using theabsorbent composite 195. Additionally, an acquisition layer 48 could beadded to improve performance.

Backsheet

As mentioned above, the diaper 10 employs a backsheet 60 that covers thecore 46 and preferably extends beyond the core 46 toward the side edges90 and end edges 92 of the diaper 10. In one aspect of the invention,the backsheet 60 is constructed from a single-layered material sheet ofabsorbent composite 195. In such a configuration, fabric 125 ispositioned as an outer surface of the backsheet 60.

Additionally, an alternative structure could be used for gel blocking.For an application using gel blocking, a backsheet of the inventivedisposable absorbent article is relatively thin and provides improvedflexibility. When dry, the backsheet is soft and breathable, but uponwetting, a thin, gel blocked layer is formed (i.e., on the inner surfaceof the backsheet) which renders the backsheet substantially liquidimpervious. The gel blocked layer is formed by the swelling of the SAPparticles 135.

Topsheet

Similarly, the absorbent composite 195 may be utilized with or as thetopsheet of an absorbent garment. The topsheet 50 is preferably soft,compliant, exhibits good strikethrough and a reduced tendency to rewetfrom a liquid pervious material. The topsheet 50 is placed in closeproximity to the skin of the wearer when the diaper 10 is worn. In thisway, such a topsheet 50 permits bodily discharges to rapidly penetrateit so as to flow toward the core 46 more quickly, but not allowing suchdischarges to flow back through the topsheet 50. The topsheet 50 may beconstructed from anyone of a wide range of liquid and vapor permeablehydrophilic materials. The surface(s) of the topsheet may be treatedwith a surfactant so as to facilitate liquid transfer therethrough,especially at a central zone or area of the topsheet located over thecore and an inner surface of the core. The topsheet may also be coatedwith a substance having rash preventing or rash reducing properties(e.g., aloe vera).

In one example, the topsheet 50 is formed from an absorbent composite195 that covers substantially the entire area of the disposal absorbentarticle 10, including substantially all of the front waist region 12,back waist region 14, and crotch region 16. Further, the ear layer ofthe inner region 18 is formed from the same single topsheet materialand, thus, may be referred to as being unitary with the topsheet 50 informing lateral extensions of the topsheet material. Alternatively, thetopsheet 50 may be formed from multiple different materials which varyacross the width of the topsheet 50. Such a multiple piece design allowsfor creation of preferred properties and different zones of thetopsheet.

Absorbent Core

In addition to or as an alternative to the above examples, the absorbentcore of the disposable absorbent article may be constructed from theabsorbent composite 195, laminated layers of absorbent composite 195(not shown) or multiple layers of SAP particles 135 and fabric. FIGS. 11and 12 depict cross sectional views of alternating layers of SAPparticles 135 and fabric that form a multi layered absorbent composite700 and 900, respectively. As shown in these drawings, the core 46 maybe comprised of distinct layers of SAP particles 135 (710 and 910). Thelayers may be uniform or non-uniform, depending on the intendedapplication. In the non-uniform multi layered absorbent composite 900,the concentration of SAP particles 135 may vary within a given layer,between layers, or combinations thereof.

FIG. 11 depicts a composite structure 700 in which SAP particle layers710 and fabric layers 720 are alternated to form the completed compositestructure 700. The layered design can also be constructed by bondingtogether sheets of absorbent composite, folding a unitary sheet ofabsorbent composite, or constructing absorbent composites with multiplelayers during the manufacturing process. In folded applications, thecomposite fold may be a C-fold, Z-fold, V-fold, W-fold or combinationsthereof. Further, the folds may be open, closed, or overlapping.

FIG. 12 depicts multi layers absorbent composite 900. As shown in FIG.12, high concentrations areas of SAP particles 910 may be strategicallypositioned to provide additional absorbency in specific regions such asthe crotch of an absorbent article. One skilled in the art understandsthat the high concentration areas may be offset to control the amountand direction of liquid penetration. Additionally, the layer with zonesof high concentrations may be combined with layers of substantiallyuniform layers. Alternatively, the high SAP concentration areas can beformed by positioning multiple layers of absorbent core.

The core may be configured to extend substantially the full lengthand/or width of the disposable absorbent article. Preferably, however,the core is disposed or is otherwise concentrated at the crotch regionof the article. In various embodiments, the core extends to the edges ofthe article and the SAP particles 135 are concentrated in the crotchregion or another target zone of the article. In still anotherembodiment, the particles can be a combination of SAP particles, skincare particles such as ion exchange resins, deodorant, anti-microbialagents, binder particles, or other beneficial particles.

Containment Walls

Now turning to FIGS. 13 and 14, the disposable absorbent article 10utilizes a pair of containment walls or cuffs 34 which employ theabsorbent composite 195. Each containment wall 34 is a longitudinallyextending wall structure preferably positioned on each side of the core46 and spaced laterally from the longitudinal center. The longitudinalends of the walls 34 may be attached, for example, to the topsheet 50 inthe front and rear waist regions 12 and 14. Preferably, the ends of thecontainment wall 34 are tacked down inwardly and attached, for example,by adhesive to the web structure. Such a construction effectively biasesthe containment wall 34 inwardly and is generally considered to causecontainment wall 34 to exhibit improved leakage prevention properties.

FIG. 13 provides a cross-sectional view of a diaper 10. The diaper 10includes backsheet 60, absorbent core 46, acquisition layer 48, andtopsheet 50. As shown in FIG. 13, the core is an absorbent composite195. The diaper 10 also includes a pair of containment walls or cuffs 34which are formed by folding the topsheet 50 and wrapping it about theends of the absorbent composite 195. Alternatively, the absorbentcomposite 195 in the cuffs 34 may be distinct from the absorbent core46.

Preferably, the containment walls 34 are equipped with elastic members38, which extend along a substantial length of the containment walls 34.In a common application, the elastic members 38 are placed within thecontainment walls 34, preferably at the top of the containment walls 34while in a stretched condition and the glued to the containment walls atleast at their ends. When released or otherwise allowed relaxing, theelastic members 38 retract inwardly. When the article 10 is worn, theelastic members 38 function to contract the containment walls 34 aboutthe buttocks and the thighs of the user in a manner, which effects aseal between the article 10, the buttocks and the thighs. The core 46may be a single sheet of absorbent composite 195 or multilayered, asdescribed above.

FIG. 13 depicts the configuration of the containment walls 34 when it issoft and dry. FIG. 14, on the other hand, depicts the containment wallsafter wetting, in which the absorbent composite 195 has swollen todispose the containment walls 34 in a resiliently, erect position.Unlike traditional leg cuffs in the prior art, the resiliently erectcontainment walls 34 resists flattening (e.g., when the wearer sitsdown) and, thereby, ensures leakage prevention, especially of explosive,liquefied bowel movements and rapid discharges of urine.

Optional Layers

The disposable absorbent article may employ additional layers includingan acquisition layer or surge layer 48, preferably situated between thetopsheet and the core (e.g., FIG. 10). One function of such anacquisition layer is to spread out or disperse liquid flow so thatliquid is distributed more evenly over the core surface. This serves toslow down the flow so that the liquid has adequate time to be absorbedby the core. The acquisition layer also serves to prevent the core frombeing saturated locally, while a substantial remainder of the core isnot absorbing any liquid.

Tape Tabs

The disposable absorbent article must be secured to the wearer. This ismost important with respect to diapers since diapers are not pulled upby the wearer, like training pants or incontinent briefs, but arefastened around the wearer. Securing elements compliment the elasticmembers by effecting a quasi-seal between the wearer and the waistbandand leg cuffs, so that liquid is contained within the article which isthen absorbed; in other words, so that it does not leak through gapsbetween the wearer and the edge of the article. The securing elementsmay be adhesive, mechanical fasteners hook and loop features, orconceivably strings, i.e., anything that will secure one end of thearticle to the longitudinally opposite end. The securing elements mayalso be co-adhesive such that they adhere to each other but not othermaterials.

In the examples shown in the Figures (see, e.g., FIG. 10), the article10 is affixed to the wearer by tape fasteners 26 which are permanentlyaffixed to (e.g., sewn directly into) the backsheet 60. Tape fasteners26 are contacted with the transversely opposite ear 22 extending fromthe backsheet, where they remain affixed due to adhesive compoundapplied to the fasteners 26. Alternatively, the article 10 may betraining pants, pull-on diapers, and the like. In this configuration,the article 10 mayor may not have tape fasteners 26.

Waistband

Waistbands employing elastic members 52 are positioned along thetransverse portion of the article 10 so that when worn, the waistbandsare positioned along the waist of the wearer. Generally, the waistbandpreferably creates a quasi-seal against the waist (transverse elasticmembers 52) so that liquid waste does not leak from the regions betweenthe waist elastic and the waist of the wearer. The quasi-seal issignificant because, although the liquid may be eventually absorbed byfiller material, the assault of liquid by the wearer may overwhelm theabsorption rate capacity of the filler material. Hence, the waistbandscontain the liquid while it is being absorbed. Secondly, the waistbandsmay have a capacity to absorb liquid (see, e.g., U.S. Pat. No.5,601,544, which is hereby incorporated by reference).

Aggregate (and Embossing) Patterns and Material Selection for FlufflessAbsorbent Composites

The simplified illustrations of FIGS. 15A-15D present absorbentcomposites 510 with particularly advantageous arrangements of aggregates512 of absorbent particles, according to the present disclosure (withlike reference numerals used to indicate like elements). Referring firstto FIG. 15A, each of the aggregates on the absorbent composite 510 arerepresented by the diamond-shaped enclosure 514 in the pattern. Inpreferred embodiments, SAP is employed as the absorbent particles in theaggregates. Furthermore, SAP aggregates in each of FIGS. 15A-15D arepreferably maintained in place and stabilized by physical entrapments orcontainers provided by the engagement of a first fabric disposedgenerally above the SAP aggregate with a second fabric disposedgenerally beneath the SAP aggregate. Thus, in an alternative view ofFIG. 15A, the diamond units represent the outline of the containers orpockets, reflecting in particular embodiments, the engagement of the topfabric with the bottom fabric, as previously described herein.

As described previously, the absorbent performance of the SAP can beaffected by the size and structure of the container. As SAP becomes moresaturated, its permeability is reduced. Water cannot pass through theSAP particle due to the high level of water already contained within theSAP particle and eventually the SAP can completely halt the passage offurther fluid through it. This is known as gel blocking. Also, as SAPbecomes more saturated, it swells and its volume increases. By confiningthe SAP in a small container of fixed volume it is possible to restrictthe swelling of the SAP and prevent it from reaching its highestsaturation levels (and by consequence stop the SAP from reaching itslowest levels of permeability). The degree to which the SAP particle isrestricted depends on a number of factors, including: the nature andsize of the container, the size and frequency of any breaks in thecontainer (e.g., along the side walls), the amount of SAP disposed inthe container, and the amount of fluid absorbed by the SAP. Further, theperformance properties of SAP are affected by its degree of saturation.Specifically, absorbent composite properties such as permeability,absorption rate, capillary pressure (arising from the void space in thecomposite) will vary significantly as the SAP changes from dry to fullysaturated. In accordance with a method of the present disclosure, targetor optimal performance of the SAP may be achieved by changing the sizeof the container and/or the SAP concentration so as to physicallyconstrain the swelling of the SAP and limit the maximum saturation pointof the SAP. By incorporating these physical features, preferred levelsof permeability or a preferred absorption property may be achieved intarget regions of the absorbent core. Thus, by playing with the twovariables of pocket size and the amount of SAP in the pocket, theminimum permeability of that container or pocket may be “set”. Pocketsin some regions of the diaper may be prevented from gel blocking and thepermeability of that region of the core may be optimized. A gradient ofpocket size may also be established to obtain maximum flow andutilization of the absorbent core. This gradient will be radiate fromthe target zone towards the ends or sides of the diaper.

The various arrangements of containers or pockets also promote SAP andcore utilization and prevent fluid from bypassing the containers.Ideally, fluid should leak or flow from container to container as theSAP reaches the maximum level of saturation which is set either by theproperties of the SAP or the volume of the pocket into which it isexpanding. Applicants contemplate that, in some of the previouslydescribed composites or arrangements of pockets (see FIG. 6), there maybe a tendency for fluid to leak between the pockets. That is the fluidruns along the channels formed by embossing lines and does not enter thecore. To mitigate this tendency, arrangements or patterns for thecontainers are preferably ones that minimize or eliminate short anddirect routes (as may be established along embossing lines) of fluidflow from the core center to the side margins of the core. Specifically,embossing lines for the fluid to flow along from the center of the coreto the side edge of the core. To illustrate, containers or pocketsshaped as diamonds are preferred to ones formed in squares orrectangles, because the diagonal lines or channels formed by the diamondcontainers are longer and more circuitous. Circles are also effective ifpacked in a way that does not present channels that flow quickly to theedge. In more preferred arrangements, fluid flow is forced to changedirections one or more times before flowing through the side of thediaper.

An absorbent core for a baby diaper or adult incontinence product isrequired to absorb fluid quickly, in an anatomically aligned region ofthe core, absorb all the fluid without leaking at the sides or ends ofthe product and hold on to that fluid without wetting the user's skinparticularly when under the pressure caused by the user's bodyweight.This present disclosure accomplishes that by providing regions of thecore having different performance parameters defined by the size of thecontainers retaining the SAP, as well as the arrangement of thecontainers. Thus, a core may be designed to attain optimized performancecharacteristics by changing the size of the pocket and/or theconcentration of SAP within that pocket.

In certain arrangements shown here, design features are combined toprovide a core that is less likely to leak, absorbs wetness fast, andprovides a dry, comfortable feeling for the user. At the crotch regionof the core, the container size and SAP loading are optimized to providean open structure, with high permeability, resulting in fast acquisitionor distribution of fluid away from the point of insult and away from theuser's skin. Permeability is maintained even when the SAP is swollen dueto the physical constraints of the container restricting furtherswelling. This allows the liquid to spread more efficiently towards theregions further away from the target zone (crotch area), and contributesto better performance and utilization of the absorbent core. At regionsaway from the crotch region, such as regions proximate the periphery ofthe core and beyond, permeability is reduced to slow down the fluid.Absorption capacity is increased by the larger pockets allowing the SAPto swell more fully and hold on to more fluid.

In FIG. 15A, large diamond shaped containers or pockets 514 of absorbentparticles aggregate 522 are present in a region anatomically alignedwith the point of insult. The containers then gradually reduce in sizetoward the sides and front and rear margins or edges of the core 510.There are three distinct regions of containers. In the crotch region“A”, large diamond shaped pockets are provided. Adjacent and surroundingthe crotch region is an intermediate region “B” of pockets of smallersize than those in the crotch region (A). Among other things, thesmaller pockets of this intermediate region (B) present breaks in thepotential fluid flow around the SAP aggregates and along embossinglines. As described previously, the presentation of such barriers todirect escape of fluid flow through the side margins prevents leakageand promote utilization of the SAP aggregates. Finally, a third region“C” of pockets is present near each of the end edges of the core 510populated by even smaller sized pockets of SAP aggregates.

FIG. 15B illustrates a second exemplary arrangements of SAP aggregates522 and pockets 514. In this example, small, diamond shaped pockets 522are disposed in the region anatomically aligned with the point of fluidinsults. The pockets then gradually increase in size in regions disposedtoward the sides and front and rear edges of the core. The twoarrangements (in FIGS. 15A and 15B) provide alternative ways ofstructuring the expected flow gradient and as well, handling of theliquid insults. The absorbent composite and arrangement of pockets inFIG. 15A may provide for a center region with a larger capacityinitially, but which, over time, will redistribute liquid in its voidvolume, or from subsequent liquid insults, to smaller adjacent pocketsor cells. With the pattern of FIG. 15B, the center region may beequipped with smaller capacity initially, which will cause the liquid totravel to larger cells. It may also generate a surface topography thatprevents leakage from the sides and ends of the diaper, i.e., “dams”will be created that intercept and absorb surface flow.

FIGS. 15C and 15D provide alternate arrangements wherein circularpockets for SAP aggregates are employed. In FIG. 15C, large, circularshaped pockets are present in a region anatomically aligned with thepoint of insult. The pockets 534 gradually reduce in size toward thesides and front and rear edges of the core 530. The pattern is similarto that employed in FIG. 15A but with circular pockets rather thandiamond-shaped ones. Many of the characteristics of the arrangement inFIG. 15A translate to the design of FIG. 15C, however. Unlike a diamondshaped pocket, it is not possible to produce a perfectly close packedpattern with circular shaped pockets and the resulting space between thecircular pockets could be disposed in a number of ways. It is envisagedthat the space between the circular pockets could either be completelyembossed (i.e., have large embossed, thermally bonded regions betweenthe pockets), partially embossed or not embossed. The spaces could alsocontain SAP or be free of SAP.

FIG. 15D illustrates a further embodiment of the present invention, witha pattern analogous to that found in FIG. 15B. In this example, small,circular shaped pockets 544 are disposed in the region anatomicallyaligned with the point of fluid insults. The pockets 544 graduallyincrease in size in regions disposed towards the sides and front andrear edges of the core. Again the space between the pockets 544 could beutilized in a number of ways as described above.

It should be noted that arrangements and embossed patterns are notlimited to employment of diamond shaped pockets or circular shapedpockets. Other shapes are contemplated. Some arrangements may evenutilize different pocket shapes within the same pattern.

The following table summarizes the characteristics of the differentpocket sizes, assuming the SAP concentration remains uniform throughoutthe core.

TABLE 1 Summary of Performance by Product Size and degree of SAPSaturation SAP Saturation Small Pocket Size Medium Large Dry Very highpermeability (0%) Moderate absorption rate High capacity remaining LowHigh permeability High permeability High permeability (10-20%) Highabsorption rate High absorption rate High absorption rate Low capacityremaining Moderate capacity High capacity remaining remaining MediumHigh permeability High permeability High permeability (20-60%) Nofurther absorption Low absorption rate High absorption rate Low capacityremaining Moderate capacity remaining High — Moderate permeability Lowpermeability (60%+) No further absorption Low absorption rate Lowcapacity remaining

Systems, Method, and Structures for Absorbent Particles Constructionand/or Stabilization

In a further variation of providing an absorbent composite according tothe present disclosure, one or more of the nonwoven webs employed inprevious examples is replaced with a more open structure. Examples ofsuch a nonwoven include, carded PET webs, airthrough bonded nonwovens,resin bonded nonwovens and non-absorbent air-laid structures. Materialsknown as acquisition and distribution layers (ADL) are included in thislist of suitable materials. The resulting structure provides analternative means for containing absorbent particles and morespecifically, within a fibrous network but without using an absorbentmatrix of fibers (i.e., without pulp). The structure promotes thedistribution of the SAP within a network of fibers provided by thenon-woven web layer. This distribution of SAP particles into the moreopen web provides, among other things, a mechanism for furtherstabilization of the SAP within the nonwoven simply through entanglementof the particles within the fibrous network.

FIG. 16 A illustrates a composite structure as previously described. Thecomposite employs a non-woven as a bottom layer (NW1) and a top layer(NW2) to sandwich a layer of SAP material (SAP). FIG. 16B illustrates analternative structure, wherein a bulky non-woven (“bulky” NW1) isemployed as a base layer. The bulky non-woven layer NW1 provides fibersthat extend outward and entangle SAP particles. Such entanglement withthe fibers in the more open material leads to stabilization of the SAPwithin the absorbent composite. In a manufacturing process, SAPparticles applied onto a sheet or web of the bulky woven may beenergized so as to promote penetration into the fibrous network of themore open nonwoven web. The effect of gravity on the particles may besufficient to promote the desired penetration as the SAP particles arelaid down onto the web. Techniques such as vacuum or vibration could beused to further enhance the penetration of the SAP particles into theopen, fibrous network.

Stabilization of the SAP prevents movement of the material duringprocessing, storage and use. In exemplary embodiments, the absorbentcomposite or core may employ the “bulky noven” structure (as in FIG.16B) for stabilizing the SAP in addition to the use of adhesive andcontainers or pockets of SAP aggregates, as previously described.

It should also be noted that the more open nonwoven material can provideadditional performance features. These include faster acquisition offluid and improved dryness (rewet) for the user. Also, the absorbentmatrix will feel softer (spongier) than “flat” nonwoven webs, and willprovide a more flexible composite. This results in greater comfort forthe user and a better fit around the contours of the user's body leadingto less chance of leakage.

Referring now to the illustrations in FIGS. 17A-17B, the exemplaryabsorbent composite is preferably provided with top layer of “bulky”nonwoven. The illustrations may be regarded as simplifiedcross-sectional views of the composite in FIG. 15A. Because thesubstrate used to contain the SAP is an open structure nonwoven, it ischaracterized by large pores (˜2000 microns). Embossing will set andstabilize the local pore structure of the bulky, resiliant fiber websubstrate. Areas wherein the embossing pattern is small (utilizes smallcontainers) (FIG. 17A) creates smaller pores (see FIG. 17A) compared toareas with larger embossing patterns (FIG. 17B) which creates largercapillary pores (17B). In other words, the smaller inter-fiber distancecharacterized by the smaller patterns lead to higher densities andhigher capillarity. The larger patterns provide greater inter-fiberdistances which lead to low density and low capillarity. The result ofthis combination of pockets across the core is an optimized wickingstructure, as illustrated in FIG. 17C. With larger pores situated in thetarget area and smaller pores away from the insult point, an effectiveconduit for fluid flow results. This conduit may be utilized totransport liquid against gravity more efficiently. (See illustration ofliquid movement in FIG. 17c ). Such an advantageous structure can becreated within the nonwoven substrate by the appropriate choice ofembossing patterns hence allowing the liquid to spread further,enhancing core utilization and intake.

In further embodiments and in reference to FIGS. 17C and 17D, 3-Dpatterns or contours may be formed during use (uptake of liquid) as aconsequence of SAP swelling. As shown in FIGS. 17C and 17D, differentsize pockets provide differences in swelling capacities, which in turnlead to differential swelling. In one respect, dams may be created bythe pockets with greater swells (i.e., larger pillows). This structuralconsequence helps to reduce side and waist leakage. In most cases,uncontrolled liquid (liquid pooling on the surface of the product) leadto product leakage. The 3-D topography generated as SAP swells isdefined by the embossing pattern size/frequency. An absorbent core thatcan self-generate a surface topography can inhibit cross-directionalsurface flow (to prevent side leakage) or discourage leakage at thewaist region (longitudinal ends of the core). The structure andarrangement of pockets in FIG. 15A would be well suited to achieve theseproperties in an absorbent core.

Further Exemplary Methods and Systems for Making an Absorbent CompositeEmploying SAP.

In a method referred to as profiling, the SAP dosing rate is varied toproduce a profiled core. See e.g., U.S. patent application Ser. No.12/925,765 for profiled core designs, which document is incorporated byreference and made a part of the disclosure. The profiled core structureprovides improved diaper performance by providing more absorbentmaterial in areas of the core where it is needed. The profile may alsobe achieved by stacking multiple layers of the absorbent composite, butat different lengths (e.g., short top core, full length bottom core). Amore efficient solution may be to vary the SAP dosing rate duringapplication of the SAP and align the high SAP dose areas with the crotcharea of the diaper when the core is converted in the diaper line. Such amethod may be more efficient as it utilizes less nonwoven material thanthe stacked core. It is also cost effective.

In one embodiment, a powdered hotmelt adhesive is mixed with the SAP toprovide additional bonding. The SAP and adhesive mixture is distributedbetween the two nonwoven webs and the hotmelt adhesive is “activated” bypassing the composite through a heating device. Suitable devices includeheated rollers, infra-red heater and the like. The adhesive melts andbonds the SAP and nonwovens together. This can also be combined with thepatterned embossing/ultrasonic processes to produce pocket patterns asdescribed previously. Typically, the adhesive/SAP is mixed at a ratio of10 to 100 parts SAP to 1 part adhesive by weight (1-10% adhesive byweight). Too much adhesive will limit the absorption performance of theSAP, while too little adhesive may sacrifice structural integrity.Preferably, the adhesive is applied at a rate of about 1 to 2 particlesof adhesive per particle of SAP. The exact rates may be worked out ifthe average particle size and density of the SAP and adhesive is known.

The absorbent composites described thus far are well suited formanufacturing in both offline and online manufacturing processes. In theoffline process, the core machine stands separate to any other processand produces rolls, spools or boxes of festooned material that is thendelivered to the diaper converting line. Typically, but not necessarily,the machine associated with the product of FIGS. 6-7, as describedpreviously, would produce a wide sheet of the absorbent composite. Theproduct is then slit to produce a number of rolls of material for use onthe diaper converting line, e.g., a 1.5 m wide machine would produce 15rolls of material at 100 mm width. In the offline process, the offlinemachine will typically run at speeds much slower than the diaperconverting line. In the online process, the core machine is part of thediaper converting line and the core is made a part of the diaperconverting process. The output speed of the core machine must match thespeed of the diaper converting line and the width of the core will matchthe width of the core in the product.

In an offline process depicted in FIG. 18A, an SAP sandwich is formedhaving a substrate A, a second substrate B and an SAP coating disposedbetween the two substrates. In one embodiment, the SAP is immobilized bybonding the two substrates together to contain the SAP in discreteplanar volumes between the layers. One or a combination of the followingmethods for SAP stabilization may be employed. In a first process, heatembossing or ultrasonic bonding is employed to fuse the substrate layersin a defined pattern. In a second process, an adhesive is applied to oneor both of the substrate inner surfaces. The two substrates are thenstrategically bonded together according to an advantageous embossingpattern. Thirdly, a thermal binder, such as low melting adhesiveparticles, may be mixed with the SAP particles. External heating is thenapplied to the composite to activate or melt the adhesive, therebybinding the particles to the substrate and to each other. Here, apatterned embossing step may be used to enhance the lamination qualitywhile maintaining a more open SAP layer structure for enhanced liquidintake. If a patterned is not desired, a smooth calendar roll (notpatterned), may also be employed to bond the cover layer to the SAPlayer to produce the sandwich structure.

In an online process, the core forming process is directly coupled tothe diaper converting process. The SAP sandwich structure is formed aswith the first and second process discussed above, at speeds 3-4 timesthat of the offline process. The third method may not be suited to thefaster online process because of the short dwell time required to heatand activate the thermal binder that is mixed in with the SAP. Theoffline process is designed to produce a wide material at slower speeds.The material output is then slit into narrower widths to supply severaldiaper lines. In contrast, the online process is designed to produce anarrow (1-wide) material at higher speeds and supply core material foronly one diaper machine at a time.

So, in a preferred embodiment using the offline method according to thethird method described above, a small quantity (10% or less) of hot meltparticles is mixed in with the SAP. This particle mix is then uniformlydeposited on substrate A, subjected to radiant IR heating to melt theadhesive particles. The second substrate B is then laid on top while thematerial is still hot. The layers are immediately laminated togetherusing heat embossing with a patterned roll/smooth anvil embossingsystem. Table 2 below summarizes the process and provides certainparameters of a preferred embodiment

TABLE 2 Exemplary Offline Process of Manufacturing Using Hot MeltAdhesive Core SAP BW, Bonding Structure Substrate A gsm Hot MeltActivation Substrate B Pattern A 20-80 gsm 150-750 Abifor 1605, IRHeating Tissue Diamond, ADL web 5-10% 22 × 50 mm

A coating line manufactured by Santex, Tobel, in Switzerland may providethe SAP scattering technology, IR heating and web handling. See e.g.,FIG. 18B. The SAP material is chosen according to its suitability forthe application, but in general, SAP with high retention capacity andhigh absorbency under load are preferred, for example, CentrifugeRetention Capacity (CRC) of from 20-40 g/g, a Pressure Absorbency Index(PAI) greater than 100 g/g An exemplary SAP is M-151 manufactured byNippon Shokubai. A suitable hot melt adhesive is low melting EVApolymer, Abifor 1605, 0-200 micron particle size grade, which iscurrently available from Abifor Powder Technology, Switzerland. Thebonding pattern specified for this embodiment is an elongated diamondwith a major axis length of 50 mm oriented in the MD direction and aminor axis length of 22 mm. See e.g., FIG. 18C.

The present disclosure is, therefore, well adapted to carry out theobjects and attain the ends and the advantages mentioned, as well asothers inherent therein. While presently preferred embodiments (in theform of a diaper) have been described, numerous changes to the detailsof construction, arrangement of the article's parts or components, andthe steps to the processes may be made. For example, the varioustopsheets, backsheet, absorbent core, containment walls and otherabsorbent composite structures may be utilized in other parts of thearticle or with other articles other than diapers. Such changes willreadily suggest themselves of those skilled in the art and areencompassed within the spirit of invention and in the scope of theappended claims.

Although the present disclosure and its advantages have been describedin detail, it should be understood that various changes, substitutionsand alterations can be made herein without departing from the inventionas defined by the appended claims. Moreover, the scope of the presentapplication is not intended to be limited to the particular embodimentsof the process, machine, manufacture, composition of matter, means,methods and steps described in the specification. As one will readilyappreciate from the disclosure, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized. Accordingly, the appended claims areintended to include within their scope such processes, machines,manufacture, compositions of matter, means, methods, or steps.

What is claimed is:
 1. A disposable absorbent article, comprising: achassis body defined by a first end margin and a second end marginlongitudinally spaced from the first end margin, the end marginspartially defining front and back waist regions that are fastenableabout a waist of a user; a topsheet; a backsheet; and an absorbentcomposite disposed between the topsheet and backsheet, the absorbentcomposite including a first fabric; a second fabric bonded to said firstfabric; and absorbent particles adhered between said first and secondfabric; and wherein the first fabric is intermittently attached to thesecond fabric to define a plurality of containers situated between thefirst fabric and the second fabric and containing an aggregate ofabsorbent particles; and wherein the absorbent composite includesregions of containers of absorbent particles aggregates including aprimary region having containers of a first size and a secondary regionhaving a plurality of containers of a second size different from thefirst size; and wherein the topsheet and backsheet define longitudinaland lateral margins of the chassis body.
 2. The disposable absorbentgarment of claim 1, wherein the primary region corresponds a crotchregion of the article, said crotch region being located centrallyintermediate the longitudinal margins of the chassis body.
 3. Thedisposable absorbent garment of claim 2, wherein containers of theprimary region have perimeters that are greater than perimeters ofcontainers in the secondary region.
 4. The disposable absorbent garmentof claim 3, wherein the containers of the secondary region surround theprimary region.
 5. The disposable absorbent garment of claim 4, whereinthe absorbent composite further includes end regions having containersof a size different from the size of containers in the secondary region;and wherein the secondary region is intermediate the primary region andan end region.
 6. The disposable absorbent garment of claim 5, whereineach of the end regions have containers with perimeters that aresubstantially smaller than the perimeters of containers in the secondaryregion.
 7. The disposable absorbent garment of claim 5, whereincontainers of the end regions have perimeters that are substantiallythan the perimeters of containers in the secondary region.
 8. Thedisposable absorbent region of claim 5, wherein the primary regionfurther includes a second class of containers, the second class ofcontainers having perimeters that are substantially smaller than a firstclass of containers.
 9. The disposable absorbent garment of claim 8,wherein the containers of the second class are positioned to fill voidsbetween adjacent containers of the first class.